Automated fastening machine using a compound contour vacuum track for automation of final assembly from the interior of a fuselage

ABSTRACT

A compound contour vacuum track, and an automated fastening machine using the track, for automation of final assembly inside an aircraft fuselage. The track is mounted at an angle to a surface, such as an inside surface of the fuselage, wherein the surface has one or more holes through which fasteners are inserted. The automated fastening machine is mounted on the track to traverse the track while performing fastening functions and steps. The automated fastening machine includes a carriage, arm, and end effector, wherein the arm is mounted on the carriage and the end effector is mounted on the arm. The carriage is attached to the track for positioning the arm and end effector, the arm is attached to the carriage for positioning the end effector, and the end effector is attached to the arm for installing the fasteners into the holes of the surface.

CROSS REFERENCE TO RELATED APPLICATION

This application is related to the following co-pending andcommonly-assigned application:

U.S. Utility application Ser. No. 15/365,426, filed on Nov. 30, 2016, byKwok Tung Chan, Tanni Sisco, John Hartmann, Scott Tomchick and FrankCharles Mestemacher, entitled “COMPOUND CONTOUR VACUUM TRACK FORAUTOMATION OF FINAL ASSEMBLY FROM THE INTERIOR OF A FUSELAGE,” whichapplication is incorporated by reference herein.

BACKGROUND INFORMATION 1. Field

The present invention relates to factory level automation, and inparticular to a compound contour vacuum track for automation of finalassembly from the interior of a fuselage.

2. Description of the Related Art

Factory level automation for aircraft assembly includes the automateddrilling of holes and insertion of fasteners. For example, the joiningof different sections of a fuselage may be automated in such a manner.

The fuselage may comprise a monocoque or semi-monocoque shell, wherein aseries of hoop-wise frames in the shape of the fuselage cross sectionsare attached to longitudinal stringers that are covered with a skin ofmaterial. Most modern large aircraft use several large sections, whichare then joined by fastening, riveting or bonding to form the completefuselage.

In aircraft assembly, limited access to structures within the fuselagehas posed a problem for automation. Currently, only the drilling ofholes and the insertion of fasteners, such as lockbolts, has beenautomated, from the outside of the fuselage.

For example, an automated multi-axis drilling machine positioned outsidethe fuselage is currently used for the drilling of holes and theinsertion of fasteners. The multi-axis drilling machine comprises acarriage with an end effector traveling on dual tracks. The end effectordrills holes in fuselage and inserts fasteners into the holes.

Currently, manual fastening of collars onto the fasteners is performedon the inside of the fuselage. Specifically, the process inside thefuselage requires mechanics to install gap management tools and provideclamps for the drilling of holes and the insertion of fasteners.Mechanics also need to follow and align the multi-axis drilling machinepositioned outside the fuselage, and manually install and swage collarsfrom inside the fuselage.

However, manual fastening poses a number of issues, including ergonomicand safety considerations, product lead time and rework. On the otherhand, the track used for the automated multi-axis drilling machinepositioned outside the fuselage is not suitable for use inside thefuselage.

What is needed, then, are improved methods of factory automation,especially for final assembly inside a fuselage. The present inventionsatisfies this need.

SUMMARY

To overcome the limitations in the prior art described above, and toovercome other limitations that will become apparent upon reading andunderstanding the present specification, the present invention disclosesan automated fastening machine, using a compound contour vacuum track,for automation of final assembly inside an aircraft fuselage.

The devices and methods of the present invention are embodied in manyways, including, but not limited to, the following embodiments listedbelow.

1. A device or method for fastening a structure, comprising an automatedfastening machine, for performing fastening functions, including acarriage, arm, and end effector, wherein the arm is mounted on thecarriage and the end effector is mounted on the arm; wherein theautomated fastening machine is mounted on a track while performing thefastening functions, the track is mounted interior to a structure inorder to access a first surface of the structure, and the first surfacehas one or more holes through which fasteners are inserted; and whereinthe carriage traverses the track for positioning the arm and endeffector, the arm is attached to the carriage for positioning the endeffector, and the end effector is attached to the arm for installing thefasteners into the holes of the first surface.

2. The device or method of embodiment 1, wherein the first surface is aninside surface of an aircraft fuselage.

3. The device or method of embodiment 1, wherein the carriage includes apinion drive that engages with a drive rack on the track for moving theautomated fastening machine along the track.

4. The device or method of embodiment 1, wherein the end effector has aresync camera to align the automated fastening machine with regard toone or more features on the first surface.

5. The device or method of embodiment 1, wherein the automated fasteningmachine is aligned with another machine on an outside of the structure.

6. The device or method of embodiment 1, wherein the end effector has anormality sensor to position the end effector relative to the firstsurface.

7. The device or method of embodiment 6, wherein signals from thenormality sensor are used to rotate the arm and end effector to achievea substantially perpendicular orientation relative to the surface.

8. The device or method of embodiment 1, wherein the end effector has aclamp foot for engaging the first surface having the holes through whichfasteners are inserted.

9. The device or method of embodiment 8, wherein the clamp foot providesa clamp-up force for a one-up assembly (OUA) process used in thefastening functions.

10. The device or method of embodiment 1, wherein the end effectorinstalls the fasteners in the holes by swaging collars on the fasteners,riveting the fasteners, or torquing nuts on the fasteners.

11. The device or method of embodiment 1, wherein the end effector has afeed system for feeding collars or nuts to the fasteners.

12. The device or method of embodiment 1, wherein the end effector has apart recovery system for collecting parts resulting from the holes beingdrilled and the fasteners being installed.

13. The device or method of embodiment 1, wherein the end effector has acamera system for inspecting the holes or the fasteners.

14. The device or method of embodiment 1, wherein the automatedfastening machine is coordinated with another machine on an oppositeside of the first surface that drills the holes and inserts thefasteners in the holes.

15. The device or method of embodiment 1, wherein the track is mountedso that its width is at an angle to the first surface.

16. The device or method of embodiment 15, wherein the track is at anangle of about 90 degrees to the first surface.

17. The device or method of embodiment 15, wherein the track is at anangle ranging from about 80 degrees to about 100 degrees to the firstsurface.

18. The device or method of embodiment 15, wherein the track is mountedon a second surface at an angle to the first surface.

19. The device or method of embodiment 18, wherein the second surface isan aft pressure bulkhead of an aircraft fuselage.

20. The device or method of embodiment 1, wherein the track is mounteddirectly on the first surface.

21. The device or method of embodiment 1, wherein the carriage traversesthe track along X-Axis and Z-Axis directions, the X-Axis directioncomprises a lateral position, and the Z-Axis direction comprises avertical position.

22. The device or method of embodiment 21, wherein the automatedfastening machine is positioned along the track in at least the X-Axisand Z-Axis directions.

23. The device or method of embodiment 21, wherein the carriage movesthe automated fastening machine in the X-axis and Z-Axis directions.

24. The device or method of embodiment 21, the arm includes rails and aball screw for moving the end effector in a Y-axis directionperpendicular to both the X-axis and Z-axis directions.

25. The device or method of embodiment 24, wherein the arm includes apivot bearing for moving the end effector about an angle in a planeformed by the Y-axis and Z-axis directions.

27. A method for fastening structures, comprising: performing fasteningsteps using an automated fastening machine including a carriage, arm,and end effector, wherein the arm is mounted on the carriage and the endeffector is mounted on the arm, wherein the carriage traverses a trackmounted interior to a structure while the arm and end effector performthe fastening steps of: positioning the end effector with regard to aninside surface of the structure having a hole therein through which afastener is inserted; clamping up the inside surface using a forceapplied by the end effector; and installing the fastener insertedthrough the hole using the end effector.

28. The method of embodiment 27, further comprising aligning the endeffector with regard to one or more features on the inside surface usinga resync camera of the end effector.

29. The method of embodiment 27, further comprising aligning theautomated fastening machine with another machine on an outside of thestructure.

30. The method of embodiment 27, further comprising positioning the endeffector relative to the inside surface using a normality sensor of theend effector.

31. The method of embodiment 30, wherein the positioning step comprisingrotating the arm and end effector to achieve a substantiallyperpendicular orientation relative to the inside surface using signalsfrom the normality sensor.

32. The method of embodiment 27, wherein the clamping up step comprisesengaging the inside surface and applying the force using a clamp foot ofthe end effector.

33. The method of embodiment 32, further comprising extending the clampfoot to engage the inside surface adjacent the hole using a clampcylinder of the end effector.

34. The method of embodiment 27, wherein the force is applied for aone-up assembly (OUA) process used in the fastening steps.

35. The method of embodiment 27, wherein the installing step comprises:using a load pin slide to position a load pin underneath a collar feedtube; blowing a collar onto the load pin from the collar feed tube withcompressed air; using a side jet to hold the collar on the load pin;retracting the collar feeder tube; extending the load pin slide toposition it under the collar swager, so that the collar, while stillheld on the load pin, is positioned between feed fingers of the collarswager; moving the collar swager forward to push the collar against thefeed fingers and then moving the collar swager to clear the load pin, sothat the collar is clear of the load pin; retracting the load pin slideaway from the collar swager, wherein the collar is firmly seated in thefeed fingers of the collar swager; advancing the collar swager towardthe surface and the fastener inserted through the hole in the surface;seating the collar on an end of the fastener using the collar swager to,wherein the feed fingers of the collar swager are opened, and the collaris pushed onto the fastener; and swaging the collar on the fastenerusing a fastener installation tool.

36. The method of embodiment 35, wherein the swaging step comprises:forcing a swage die down onto the collar using the fastener installationtool, which reduces a diameter of the collar and progressively swagesthe collar material into the swage die, wherein installation iscompleted when a pintail of the fastener breaks off.

37. The method of embodiment 36, further comprising: retracting thecollar swager to strip the swage die off the swaged collar, and thenvacuuming the pintail out through a pintail return tube to a collectionpoint.

38. The method of embodiment 35, further comprising inspecting theswaged collar on the fastener.

DRAWINGS

Referring now to the drawings in which like names and reference numbersrepresent corresponding parts throughout:

FIG. 1 illustrates two sections of an aircraft fuselage positioned forbeing joined.

FIGS. 2A, 2B and 2C illustrate a system for fastening a structure usinga compound contour vacuum track and an automated fastening machineinside of an aircraft fuselage.

FIGS. 3A and 3B further illustrate a compound contour vacuum track thatis designed to follow the complex contour of the inside of the fuselage.

FIGS. 4A-4H further illustrate the automated fastening machine,according to one embodiment.

FIG. 5A provides a system overview of a control system, according to oneembodiment, and FIG. 5B further illustrates a control cabinet, accordingto one embodiment.

FIGS. 6A-6K illustrate a sequence of steps performed by the automatedfastening machine as directed by the control system, according to oneembodiment:

FIG. 7 is a flowchart that further illustrates the sequence of stepsperformed in FIGS. 6A-6K.

FIG. 8A illustrates a Bridge-style automated fastening machine; and FIG.8B illustrates a cantilevered automated fastening machine.

FIG. 9A is a flow diagram of aircraft production and servicemethodology, according to one embodiment.

FIG. 9B is a block diagram of an aircraft, according to one embodiment.

DETAILED DESCRIPTION

In the following description of the preferred embodiment, reference ismade to the accompanying drawings which form a part hereof, and in whichis shown by way of illustration a specific embodiment in which theinvention may be practiced. It is to be understood that otherembodiments may be utilized and structural changes may be made withoutdeparting from the scope of the present invention.

FIG. 1 illustrates two sections of an aircraft fuselage 10 positionedfor being joined. In one embodiment, the two sections are joined at oradjacent to an aft pressure bulkhead (APB) 11, although other sectionscould be joined at other locations as well. The aft pressure bulkhead 11is an airtight bulkhead located between the cabin and the tail of theaircraft whose purpose is to seal the rear of the plane and thusmaintain cabin pressure for the aircraft. In aircraft assembly, limitedaccess to structures adjacent to the aft pressure bulkhead 11 within thefuselage 10 has posed a problem for automation.

Currently, only the drilling of holes and the insertion of fasteners,such as lockbolts, has been automated, from an outside surface 10A ofthe fuselage 10. As noted above, an automated multi-axis drillingmachine positioned on the outside surface 10A of the fuselage 10 iscurrently used for the drilling of holes and the insertion of fasteners.The multi-axis drilling machine comprises a carriage with an endeffector traveling on dual tracks, wherein the end effector drills holesin fuselage 10 and inserts fasteners into the holes. However, manualfastening of collars onto the fasteners is currently performed on aninside surface 10B of the fuselage 10, but manual fastening poses anumber of issues. This disclosure overcomes these issues by describingan automated system of fastening for final assembly from inside thefuselage 10.

FIGS. 2A, 2B and 2C illustrate one embodiment of a system for fasteninga structure comprised of a compound contour vacuum track 12 positionedon an inside surface 10B of the fuselage 10.

As shown in FIG. 2A, the track 12 is comprised of one or more sections13 that, when assembled, indexed, aligned and mounted onto the fuselage10, are shaped to fit the inside surface 10B of the fuselage 10, alsoreferred to herein as a first surface 10B, although other surfaces maybe used as well. The sections 13 of the track 12 are aligned and mountedalong X-Axis and Z-Axis directions of the fuselage 10, wherein theX-Axis direction comprises a lateral position within the fuselage 10 andthe Z-Axis direction comprises a vertical position within the fuselage10. The arrows on the sections 13 indicate a deployment sequencing ofthe sections 13, which involves positioning and mounting a centersection 13 first, and then positioning and mounting adjacent sections 13on opposite ends of the track 12.

As shown in FIGS. 2A and 2B, the track 12 has a length (L), width (W)and thickness (T), and the track 12 is mounted so that its width W is atan angle (θ) to the first surface 10B. Specifically, the width W of thetrack 12 is not laid flush on the first surface 10B. Instead, the widthW of the track 12 is cantilevered upward at an angle θ relative to thefirst surface 10B. Preferably, the track 12 is cantilevered upward at anangle θ greater than about 0 degrees to the first surface 10B, morepreferably at an angle θ of about 90 degrees, i.e., substantiallyperpendicular, to the first surface 10B, and most preferably at an angleθ ranging from about 80 degrees to about 100 degrees, i.e., within about±10 degrees of substantially perpendicular, to the first surface 10B.

To position the track 12 in this manner, the track 12 is mounted on theaft pressure bulkhead 11, also referred to herein as a second surface11, although other surfaces may be used as well. In this embodiment, thetrack 12 is cantilevered from the second surface 11 so that the track 12is cantilevered upward at an angle θ to the first surface 10B. However,in other embodiments, the track 12 is mounted directly on the firstsurface 10B, i.e., the inside surface 10B of the fuselage 10 itself.

As shown in FIG. 2C, an automated fastening machine 14 is mounted on thetrack 12 and travels along the track 12 to perform the fasteningfunctions and steps, wherein the track 12 allows the automated fasteningmachine 14 to make contact with the first surface 10B. At any instant,the automated fastening machine 14 is positioned along the track 12 inat least the X-Axis and Z-Axis directions.

FIG. 3A further illustrates the track 12, which is a compound contourtrack 12, although it may conform to other shapes as well. The track 12is modular and is segmented into a plurality of sections 13, whereineach section 13 is aluminum, about 2 feet in length and about 28 lbs. inweight. Splices 15 are used for connecting between the sections 13. Thetrack 12 is mounted interior to the fuselage 10 on the aft pressurebulkhead 11 using one or more removable attachment devices 16, which inone embodiment comprise vacuum suction cups 16.

FIG. 3B is another view of a section 13 of the track 12 with theautomated fastening machine 14 attached, according to one embodiment.The wheels 17 of the automated fastening machine 14 are dual-vee wheels17 that sandwich the track 12, wherein the track 12 includes edge guides18 for engaging the wheels 17. The track 12 also includes a drive rack19 for engaging and moving the automated fastening machine 14 along thetrack 12, wherein the drive rack 19 is a roller rack that is integratedinto the track 12.

FIGS. 4A-4H further illustrate the automated fastening machine 14,according to one embodiment.

FIG. 4A shows the major components of the automated fastening machine14, which include an X-Axis Carriage 20, Y-Axis Arm 21 and End Effector22, wherein the Y-Axis Arm 21 is mounted on the X-Axis Carriage 20 andthe End Effector 22 is mounted on the Y-Axis Arm 21. The X-Axis Carriage20 is attached to the track 12 for positioning the Y-Axis Arm 21 and EndEffector 22, the Y-Axis Arm 21 is attached to the X-Axis Carriage 20 forpositioning the End Effector 22, and the End Effector 22 installs thefasteners into the holes of the inside surface 10B, e.g., it installscollars or nuts on fasteners inserted into the holes from the outsidesurface 10A, as described in more detail below in conjunction with FIGS.6A-6K and 7.

FIG. 4B further illustrates the X-Axis Carriage 20, according to oneembodiment, wherein the X-Axis Carriage 20 is attached to the track 12for positioning the Y-Axis Arm 21 and End Effector 22. The X-AxisCarriage 20 includes a base plate 23, drive motor 24, gear box 25,dual-vee wheels 17 and track release 26. The Y-Axis Arm 21 mounts to thebase plate 23. The drive motor 24 and gear box 25 operate a pinion drivethat engages with the drive rack 19 on the track 12 shown in FIG. 3B.The dual-vee wheels 17 are rollers guided by the track 12 and mount tothe track 12 at the edge guides 18 shown in FIG. 3B. The track release26 allows for quick detachment of the dual-vee wheels 17 from the track12.

FIG. 4C further illustrates the Y-Axis Arm 21, according to oneembodiment. The Y-Axis Arm 21 is attached to the X-Axis Carriage 20 forpositioning the End Effector 22. The Y-Axis Arm 21 includes two rails27, a ball screw 28, a control umbilical connection 29 and an A-AxisActuator 30. The End Effector 22 is mounted on the rails 27, and theball screw 28 moves the End Effector 22 along the rails 27. The controlumbilical connection 29 connects to a control cabinet, as described inFIGS. 5A-5B below. The A-Axis Actuator 30 changes the angle of theY-Axis Arm 21.

FIG. 4D further illustrates the A-Axis Actuator 30, according to oneembodiment. The A-Axis Actuator 30 is located inside the Y-Axis Arm 21,and includes a linear actuator 31 and A-Axis pivot 32 (which is the onlyportion of the A-Axis Actuator 30 visible on the outside of the Y-AxisArm 21 in FIG. 4C). The A-Axis pivot 32 is a pivot bearing forpositioning the Y-Axis Arm 21 and End Effector 22 at an angle inresponse to the operation of the linear actuator 31.

FIG. 4E further illustrates the End Effector 22, according to oneembodiment. The End Effector 22 is mounted on the rails 27 of the Y-AxisArm 21 and swages a collar onto a fastener, as described in more detailbelow in conjunction with FIGS. 6A-6K. The End Effector 22 includes apneumatic, hydraulic or electromechanical fastener installation tool 33,rotary actuator 34, collar swager 35, clamp foot 36, clamp cylinder 37,collar feeder 38, collar feeder tube 39, pintail return tube 40, resynccamera 41 and normality laser 42. The operation of these elements isdescribed in more detail below in conjunction with FIGS. 6A-6K.

FIGS. 4F, 4G and 4H further illustrate the alignment of the automatedfastening machine 14 and its X-Axis Carriage 20, Y-Axis Arm 21 and EndEffector 22. Specifically, FIG. 4F is a side view of the automatedfastening machine 14 showing the X-Axis (as a point), the Z-Axis, aY-Axis (perpendicular to both the X-Axis and Z-Axis), and an A-Axis asan angle in a plane formed by the Y-Axis and Z-Axis; FIG. 4G is a rearview of the automated fastening machine 14 showing the Y-Axis (as apoint), the Z-Axis, and the X-Axis; and FIG. 4H is a top view of theautomated fastening machine 14 showing the Z-Axis (as a point), theX-Axis, and the Y-Axis.

As noted above in FIGS. 2A, 2B and 2C, the track 12 is aligned in bothX-Axis and Z-Axis directions and, at any instant, the automatedfastening machine 14 is positioned along the track 12 in at least X-Axisand Z-Axis directions, wherein the X-Axis comprises a lateral positionwithin the fuselage 10 and along the track 12, while the Z-Axiscomprises a vertical position within the fuselage 10 and along the track12. The X-Axis Carriage 20 moves the automated fastening machine 14 inthe X-Axis and Z-Axis directions of the track 12, and the ball screw 28of the Y-Axis Arm 21 moves the End Effector 22 along the rails 27 of theY-Axis Arm 21 in the Y-Axis direction perpendicular to both the X-Axisand Z-Axis directions. The A-Axis Actuator 30 of the Y-Axis Arm 21 movesthe End Effector 22 (and the Y-Axis Arm 21 itself) about an angle in theplane formed by the Y-Axis and Z-Axis directions, which comprises theA-Axis.

FIG. 5A provides a system overview of a control system 43 used with theautomated fastening machine 14, according to one embodiment. The controlsystem 43 includes a control cabinet 44 which accepts air 45, 480V power46 and vacuum supply 47, and is connected to the automated fasteningmachine 14 via a control umbilical 48, hydraulic lines 49, collar feedertube 50 and pintail return tube 51. The control cabinet 44 may includean operator interface thereon, and may accept controls from a laptop 52and/or handheld mobile operator's pendant (HMOP) 53.

The laptop 52 includes a touch screen that allows the control cabinet 44to be operated as if the operator was at the main interface of thecontrol cabinet 44. The laptop 52 can be easily taken into the fuselage10 to allow the operator to have full control of the control cabinet 44from anywhere.

Alternatively, the HMOP 53 may be used. The HMOP 53 allows for simplemachine operation, and displays abbreviated operator messages.

One embodiment provides independent machine control. Specifically, thecontrol cabinet 44 provides commands for the inside machine, namely, theautomated fastening machine 14, and the outside machine, namely, themulti-axis drilling machine positioned on the outside of the fuselage10, is controlled independently. The benefits of this approach are thatthe software easier to develop and debug; and there is a single operatorinterface. The disadvantages of this approach are that: each outsidemachine must be paired with an inside machine; each outside machine willonly work with one specific inside machine and the machines are notinterchangeable; if an outside machine is down, then the paired insidemachine is down as well; and disruption of communication between outsideand inside machine will cause a full system failure.

Another embodiment provides dependent machine control. Specifically, thecontrol cabinet 44 provides commands for an inside machine, namely, theautomated fastening machine 14, and communicates with another controlcabinet 54 via a communications link 55, wherein the control cabinet 54provides command for an outside machine, namely, the multi-axis drillingmachine positioned on the outside of the fuselage 10, so that theautomated fastening machine 14 is coordinated with the outside machineon an opposite side of the first surface that drills the holes andinserts the fasteners in the holes. The benefits of this approach arethat machines are interchangeable, i.e. any outside machine will workwith any inside machine; communications failure between machines willnot cause complete system failure; inside machines can be connected “onthe fly” to outside machines; the outside machine handles allprogramming and has complete control over the inside machine; and only acommunication umbilical is needed to connect the inside machine to theoutside machine. The disadvantages of this approach are that:programming is more complicated; maintenance is more complicated; andeach machine has its own control cabinet 44, 54.

FIG. 5B further illustrates the control cabinet 44, according to oneembodiment. The control cabinet 44 includes a collar feeder 56 forfeeding collars, an emergency stop (E-Stop) button 57, a controlumbilical connection 58 to the automated fastening machine 14, a powerdisconnect 59, a hydraulic power unit 60 for providing hydraulic powerto the automated fastening machine 14, hoist rings 61 for hoisting thecontrol cabinet 44, and a pendant mount 62 for storing the HMOP 53.

FIGS. 6A-6K illustrate a sequence of fastening steps performed by theautomated fastening machine 14 as directed by the control system 43 toswage collars onto fasteners, according to one embodiment.

FIG. 6A further illustrates the components of the End Effector 22, aswell as a first step performed by the End Effector 22, wherein the EndEffector 22 is positioned above a surface 63 having a hole 64 thereinthrough which a fastener (not shown) is inserted. (A fastener is shownand described in conjunction with FIGS. 6I, 6J and 6K below.) In oneembodiment, the surface 63 is the first surface 10B, namely the insidesurface 10B of the fuselage 10.

In this first step, the automated fastening machine 14 uses the resynccamera 41 to align the End Effector 22 with regard to one or more datumfeatures (e.g., hole 64) on the surface 63, for example, either theinner cylindrical hole 64 walls or the rim of the hole 64. The automatedfastening machine 14 drives to a nominal target location on the track12, captures a high resolution digital image of the features on thesurface 63 using the resync camera 41, and determines an offset betweenan actual feature location and the nominal target location. The outsidemachine performs a similar process, allowing both machines to have acommon reference to the fuselage 10 and therefore each other.

Once positioned, the automated fastening machine 14 then uses thenormality laser 42 to position the End Effector 22 normal to the surface63, although other sensors may be used for this function as well.Specifically, the automated fastening machine 14 uses the signals fromthe normality laser 42 to rotate the Y-axis Arm 21 and End Effector 22to achieve a substantially perpendicular orientation of the End Effector22 to the surface 63. Once aligned, the End Effector 22 performs thefollowing steps.

FIG. 6B illustrates a next step performed by the End Effector 22,wherein the load pin slide 65 positions the load pin 66 underneath thecollar feed tube 39 and the clamp cylinder 37 extends the clamp foot 36to engage the surface 63 adjacent the hole 64. The clamp foot 36 is apressure foot and the clamp cylinder 37 is a pneumatic, hydraulic orelectromechanical cylinder capable of providing about 200 foot-pounds(lbf) of force for the clamp foot 36 on the surface 63 as a reactionforce prior to and during the drilling of the hole 64.

Specifically, the clamp foot 36 provides a clamp-up force for a one-upassembly (OUA) process used in the fastening steps. OUA is where theassembly is performed one time, namely drilled, inspected, andultimately fastened, without removal of components for deburring,cleaning, sealing, etc. In the OUA process, the outside machine uses astack of components to perform the drilling of the hole 64 in thesurface and the insertion of the fastener in the hole 64.

Here, the track 12 mounted on the aft pressure bulkhead 11 provides afoundation for the clamp-up force generated by the clamp foot 36,maintaining joint integrality and interfaces separation for the OUAstack, before the outside machine starts drilling. The outside machineis positioned such that its drill nose pushes on an opposite side of thesurface 63 (i.e., the outside surface 10A of the fuselage 10), whilenormalizing to a contour of the opposite side of the surface 63.Similarly, the automated fastening machine 14 is positioned such thatthe clamp-up force generated by the clamp foot 36 is aligned with thedrill nose of the outside machine.

FIG. 6C illustrates a next step performed by the End Effector 22,wherein a collar 67 is blown onto the load pin 66 from the collar feedtube 39 with compressed air.

FIG. 6D illustrates a next step performed by the End Effector 22,wherein the collar 67 is held on the load pin 66 with a side air jet 68and the collar feeder tube 39 is retracted.

FIG. 6E illustrates a next step performed by the End Effector 22,wherein the load pin slide 65 is extended and positioned under thecollar swager 35, so that the collar 67, while still held on the loadpin 66, is positioned between the feed fingers 69 of the collar swager35.

FIG. 6F illustrates a next step performed by the End Effector 22,wherein the collar swager 35 first moves forward to push the collar 67against the feed fingers 69 and the collar swager 35 moves back to itsmost rearward position to clear the load pin 66. At this stage, thecollar 67 is clear of the load pin 66.

FIG. 6G illustrates a next step performed by the End Effector 22,wherein the load pin slide 65 is retracted away from the collar swager35, and the collar 67 is firmly seated in the feed fingers 69 of thecollar swager 35. Directly above or behind the collar 67 is a swage die70 in the collar swager 35.

FIG. 6H illustrates a next step performed by the End Effector 22,wherein the collar swager 35 advances toward the surface 63.

FIG. 6I illustrates a next step performed by the End Effector 22,wherein a fastener 71 is inserted through the hole 64 in the surface 63,e.g., from an opposite side from the surface 63, and the collar swager35 advances toward the fastener 71.

FIG. 6J illustrates a next step performed by the End Effector 22,wherein the collar 67 is seated on the end of the fastener 71 by thecollar swager 35. Once the collar 67 is on the end of the fastener 71,the feed fingers 69 of the collar swager 35 are opened by a feature inthe side of the clamp foot 36. The collar swager 35 pushes the collar 67further onto the fastener 71, and the collar 67 is swaged by thefastener installation tool 33, which provides a force to the swage die70. In one embodiment, the collar 67 is a loose fitting metal ring thatis deformed by the die 70 around the fastener 71, which includes lockinggrooves. The die 70 is forced down onto the collar 67 by the fastenerinstallation tool 33, which reduces the diameter of the collar 67 andprogressively swages the collar 67 material into the die 70. As theforce applied to the die 70 increases, installation is completed when apintail 72 of the fastener 71 breaks off. FIG. 6K illustrates a nextstep performed by the End Effector 22, wherein the collar 67 has beenswaged on the fastener 71. The collar swager 35 is retracted to stripthe swage die 70 off the swaged collar 67, and the pintail (not shown)is vacuumed out through the pintail return tube 40 to a collectionpoint, for example, at the control cabinet 44. Finally, the resynccamera 41 may be used for inspecting the swaged collar 67 on thefastener 71.

FIG. 7 is a flowchart that further illustrates the sequence of fasteningsteps performed by the End Effector 22 in FIGS. 6A-6K.

Block 73 represents the step of positioning the End Effector 22 withregard to the surface 63 (i.e., the inside surface 10B of the fuselage10 structure) having the hole 64 therein through which the fastener 71is inserted. Specifically, Block 73 represents the step of aligning theEnd Effector 22 with regard to one or more features on the insidesurface 63 using the resync camera 41 of the End Effector 22, whichresults in aligning the automated fastening machine 14 with anothermachine (i.e., the automated multi-axis drilling machine positioned onthe outside surface 10A of the fuselage 10 structure). Block 73 alsorepresents the step of positioning the End Effector 22 relative to theinside surface 63 using the normality laser 42 sensor of the EndEffector 22, wherein the positioning comprises rotating the Y-Axis Arm21 and End Effector 22 to achieve a substantially perpendicularorientation relative to the inside surface 63 using signals from thenormality laser 42 sensor.

Block 74 represents the step of using the clamp cylinder 37 to extendthe clamp foot 36 to engage the surface 63 adjacent the hole 64 wherethe fastener 71 will be installed. Specifically, Block 74 represents thestep of clamping up the inside surface 63 using a force applied by theclamp foot 36 of the End Effector 22, wherein the force is applied for aone-up assembly (OUA) process used in the fastening steps.

The remaining Blocks 75-84 represent the step of installing the fastener71 inserted through the hole 64 using the various components of the EndEffector 22.

Block 75 represents the step of using the load pin slide 65 to positionthe load pin 66 underneath the collar feed tube 39.

Block 76 represents the step of blowing a collar 67 onto the load pin 66from the collar feed tube 39 with compressed air.

Block 77 represents the step of using a side jet 68 to hold the collar67 on the load pin 66.

Block 78 represents the step of retracting the collar feeder tube 39.

Block 79 represents the step of extending the load pin slide 65 toposition it under the collar swager 35, so that the collar 67, whilestill held on the load pin 66, is positioned between the feed fingers 69of the collar swager 35;

Block 80 represents the step of moving the collar swager 35 forward topush the collar 67 against the feed fingers 69 and then moving thecollar swager 35 to clear the load pin 66, so that the collar 67 isclear of the load pin 66.

Block 81 represents the step of retracting the load pin slide away fromthe collar swager 35, wherein the collar 67 is firmly seated in the feedfingers 69 of the collar swager 35.

Block 82 represents the step of advancing the collar swager 35 towardthe surface 63 and the fastener 71 inserted through the hole 64 in thesurface 63.

Block 83 represents the step of using the collar swager 35 to seat thecollar 67 on the end of the fastener 71, wherein the feed fingers 69 ofthe collar swager 35 are opened, the collar 67 is pushed onto thefastener 71, and the collar 67 is swaged by the fastener installationtool 33, such that the swage die 70 is forced down onto the collar 67 bythe fastener installation tool 33, which reduces the diameter of thecollar 67 and progressively swages the collar 67 material into the die70, and installation is completed when a pintail 72 of the fastener 71breaks off.

Block 84 represents the step of retracting the collar swager 35 to stripthe swage die 70 off the swaged collar 67, vacuuming the pintail outthrough the pintail return tube to a collection point, and optionallyinspecting the swaged collar 67 on the fastener 71.

Benefits

The cantilevered track 12 described herein includes a number of benefitsand advantages. One advantage is that the automated fastening machine 14only mounts to one rail, i.e., track 12, which provides for ease ofsetup. Another advantage is that the automated fastening machine 14 caneasily be removed from track 12.

On the other hand, there are some disadvantages. One disadvantage isthat the roughness of the inside surface of the fuselage 10 makes itdifficult to mount the track 12 on the inside surface of the fuselage10. Another disadvantage is that interior structures may interfere withmovement of the automated fastening machine 14 along the track 12.

Alternatives

A number of alternatives and modifications are available.

For example, although an automated fastening machine is describedherein, there are other opportunities for automation inside the fuselage10. An automated fastening machine inside the fuselage 10 may alsoinclude functions for drilling holes and filling holes (i.e., insertingbolts), deburring, vacuuming for FOD (Foreign Object Damage or Debris)control, sealing, all types of fastening (torquing, swaging, riveting),and inspection. An automated fastening machine inside the fuselage 10may include different end effectors with multiple features than thosedisclosed herein.

In another example, automation inside the fuselage 10 can alsosynchronize its functions with automation outside the fuselage 10, withor without camera assistance, for rate improvement. This is especiallytrue if used with a track that is indexed and mounted on the outside ofthe fuselage 10. As noted previously, the inside automation can workwith the outside automation for any of these additional functions, ifdesired.

In yet another example, a track inside the fuselage 10 can be flexibleor hard mounted to structures or surfaces inside the fuselage 10 with orwithout vacuum cups. Therefore, inside automation can apply to anysection of the fuselage 10, and is not limited to the aft pressurebulkhead 11.

In still another example, a track inside the fuselage 10 may not be acantilever design mounted on the aft pressure bulkhead 11.

In one example, FIG. 8A illustrates a Bridge-style automated fasteningmachine 85 wherein the dual tracks 86 are mounted to a structure orsurface 10B inside the fuselage 10 on a forward side and the aftpressure bulkhead 11 of the fuselage 10 on an aft side. One advantage isthat the Bridge-style machine 85 could potentially not have an activeA-Axis, and instead could passively normalize between tracks 86. Anotheradvantage is that, if a 200 lb. clamp is needed for all holes, thisdesign distributes the load between both tracks 86 well. Onedisadvantage to the Bridge style machine 85 is that two sets of tracks86 are required. The tracks 86 may need to be aligned to each other tocreate proper normality, wherein track 86 spacing, relative height anddistance apart will need to be controlled.

In another example, FIG. 8B illustrates a cantilevered automatedfastening machine 87 mounted to a structure or surface 10B inside thefuselage 10 on a forward side of a splice, wherein the cantileveredautomated fastening machine 87 has a reaction support forward of thatmount. One advantage is that the cantilevered machine 87 does notrequire mounting on the aft pressure bulkhead 11 with vacuum cups. Onedisadvantage is that the cantilevered machine 87 will probably need anactive B-Axis and will have to set up multiple tracks/guides. Also, thecargo floor/frame may have to react large loads.

Airplane Assembly

Embodiments of the disclosure may be described in the context of anaircraft manufacturing and service method as shown in FIG. 9A and anaircraft as shown in FIG. 9B.

As shown in FIG. 9A, during pre-production, exemplary method 88 mayinclude specification and design 89 of the aircraft and materialprocurement 90. During production, component and subassemblymanufacturing 91 and system integration 92 of the aircraft takes place,which include the factory level automation described herein, using thecompound contour vacuum track 12 and automated fastening machine 14 forautomation of final assembly from the interior of the fuselage 10.Thereafter, the aircraft may go through certification and delivery 93 inorder to be placed in service 94. While in service by a customer, theaircraft is scheduled for routine maintenance and service 95 (whichincludes modification, reconfiguration, refurbishment, and so on), thatalso includes the factory level automation described herein, using thecompound contour vacuum track 12 and automated fastening machine 14 forautomation of final assembly from the interior of the fuselage 10.

Each of the processes of method 88 may be performed or carried out by asystem integrator, a third party, and/or an operator (e.g., a customer).For the purposes of this description, a system integrator may includewithout limitation any number of aircraft manufacturers and major-systemsubcontractors; a third party may include without limitation any numberof venders, subcontractors, and suppliers; and an operator may be anairline, leasing company, military entity, service organization, and soon.

As shown in FIG. 9B, the aircraft 96 produced by exemplary method ofFIG. 9A may include an airframe 97 with a plurality of systems 98 and aninterior 99. Examples of high-level systems 98 include one or more of apropulsion system 100, an electrical system 101, a hydraulic system 102,and an environmental system 103. Any number of other systems may beincluded. Although an aerospace example is shown, the principles of theinvention may be applied to other industries, such as the automotiveindustry.

Apparatus and methods embodied herein may be employed during any one ormore of the stages of the production and service method 88. For example,components or subassemblies corresponding to production process 91 maybe fabricated or manufactured in a manner similar to components orsubassemblies produced while the aircraft 96 is in service. Also, one ormore apparatus embodiments, method embodiments, or a combination thereofmay be utilized during the production stages 91 and 92, for example, bysubstantially expediting assembly of or reducing the cost of an aircraft96. Similarly, one or more of apparatus embodiments, method embodiments,or a combination thereof may be utilized while the aircraft 96 is inservice, for example and without limitation, to maintenance and service95.

What is claimed is:
 1. A device for fastening a structure, comprising:an automated fastening machine, for performing fastening functions,including a carriage, arm, and end effector, wherein the arm is mountedon the carriage and the end effector is mounted on the arm; and a track;wherein the automated fastening machine is configured to be mounted onthe track while performing the fastening functions, the track has alength and a width, the track is configured to be mounted interior to astructure comprising an aircraft fuselage, in order to access a firstsurface of the structure comprising an inside surface of the aircraftfuselage, and the first surface comprising the inside surface of theaircraft fuselage has one or more holes through which fasteners areinserted; wherein the carriage traverses the track for positioning thearm and end effector, the arm is attached to the carriage forpositioning the end effector, and the end effector is attached to thearm for installing the fasteners into the holes of the first surfacecomprising the inside surface of the aircraft fuselage; wherein thetrack is configured to be mounted on a second surface comprising an aftpressure bulkhead of the aircraft fuselage at an angle to the firstsurface comprising the inside surface of the aircraft fuselage, and thetrack is configured to be cantilevered from the second surfacecomprising the aft pressure bulkhead of the aircraft fuselage so thatthe width of the track is cantilevered upward at an angle ranging from80 degrees to 100 degrees to the first surface comprising the insidesurface of the aircraft fuselage; wherein the track is configured to bemounted with the length of the track along X-Axis and Z-Axis directions,the X-Axis direction comprises a lateral orientation within thestructure comprising the aircraft fuselage, and the Z-Axis directioncomprises a vertical orientation within the structure comprising theaircraft fuselage; wherein the carriage is an X-Axis carriage that isconfigured to move the automated fastening machine along the track in atleast the X-Axis and Z-Axis directions; and wherein the arm is a Y-Axisarm that is configured to move the end effector of the automatedfastening machine in a Y-Axis direction perpendicular to both the X-Axisand Z-Axis directions to perform the fastening functions.
 2. The deviceof claim 1, wherein the carriage includes a pinion drive that engageswith a drive rack on the track for moving the automated fasteningmachine along the track.
 3. The device of claim 1, wherein the endeffector has a resync camera to align the automated fastening machinewith regard to one or more features on the first surface.
 4. The deviceof claim 1, wherein the automated fastening machine is configured to bealigned with another machine on an outside of the structure.
 5. Thedevice of claim 1, wherein the end effector has a normality sensor toposition the end effector relative to the first surface.
 6. The deviceof claim 5, wherein signals from the normality sensor are used to rotatethe arm and end effector to achieve a substantially perpendicularorientation relative to the surface.
 7. The device of claim 1, whereinthe end effector has a clamp foot for engaging the first surface havingthe holes through which fasteners are inserted.
 8. The device of claim7, wherein the clamp foot provides a clamp-up force for a one-upassembly (OUA) process used in the fastening functions.
 9. The device ofclaim 1, wherein the end effector installs the fasteners in the holes byswaging collars on the fasteners, riveting the fasteners, or torqueingnuts on the fasteners.
 10. The device of claim 1, wherein the endeffector has a feed system for feeding collars or nuts to the fasteners.11. The device of claim 1, wherein the end effector has a part recoverysystem for collecting parts resulting from the holes being drilled andthe fasteners being installed.
 12. The device of claim 1, wherein theend effector has a camera system for inspecting the holes or thefasteners.
 13. The device of claim 1, wherein the automated fasteningmachine is configured to be coordinated with another machine on anopposite side of the first surface that drills the holes and inserts thefasteners in the holes.
 14. The device of claim 1, wherein the angle isof 90 degrees to the first surface.
 15. The device of claim 1, whereinthe arm includes rails and a ball screw for moving the end effector inthe Y-axis direction perpendicular to both the X-axis and Z-axisdirections.
 16. The device of claim 15, wherein the arm includes a pivotbearing for moving the end effector about an angle in a plane formed bythe Y-axis and Z-axis directions.
 17. A method for fastening structures,comprising: performing fastening steps using an automated fasteningmachine including a carriage, arm, and end effector, wherein the arm ismounted on the carriage and the end effector is mounted on the arm;wherein the automated fastening machine is mounted on a track whileperforming the fastening steps, the track has a length and a width, thetrack is configured to be mounted interior to a structure comprising anaircraft fuselage, in order to access a first surface of the structurecomprising an inside surface of the aircraft fuselage, and the firstsurface comprising the inside surface of the aircraft fuselage has oneor more holes through which fasteners are inserted; wherein the carriagetraverses the track for positioning the arm and end effector, the arm isattached to the carriage for positioning the end effector, and the endeffector is attached to the arm for installing the fasteners into theholes of the first surface comprising the inside surface of the aircraftfuselage; wherein the track is configured to be mounted on a secondsurface comprising an aft pressure bulkhead of the aircraft fuselage atan angle to the first surface comprising the inside surface of theaircraft fuselage, and the track is configured to be cantilevered fromthe second surface comprising the aft pressure bulkhead of the aircraftfuselage so that the width of the track is cantilevered upward at anangle ranging from 80 degrees to 100 degrees to the first surfacecomprising the inside surface of the aircraft fuselage; wherein thetrack is configured to be mounted with the length of the track alongX-Axis and Z-Axis directions, the X-Axis direction comprises a lateralorientation within the structure comprising the aircraft fuselage, andthe Z-Axis direction comprises a vertical orientation within thestructure comprising the aircraft fuselage; wherein the carriage is anX-Axis carriage that is configured to move the automated fasteningmachine along the track in at least the X-Axis and Z-Axis directions;and wherein the arm is a Y-Axis arm that is configured to move the endeffector of the automated fastening machine in a Y-Axis directionperpendicular to both the X-Axis and Z-Axis directions to perform thefastening functions.
 18. A method for fastening structures, comprising:performing fastening steps using an automated fastening machineincluding a carriage, arm, and end effector, wherein the arm is mountedon the carriage and the end effector is mounted on the arm, wherein thecarriage traverses a track mounted interior to a structure while the armand end effector perform the fastening steps of: positioning the endeffector with regard to an inside surface of the structure having a holetherein through which a fastener is inserted; clamping up the insidesurface using a force applied by the end effector; and installing thefastener inserted through the hole using the end effector, wherein theinstalling step comprises: using a load pin slide to position a load pinunderneath a collar feed tube; blowing a collar onto the load pin fromthe collar feed tube with compressed air; using a side jet to hold thecollar on the load pin; retracting the collar feeder tube; extending theload pin slide to position it under a collar swager, so that the collar,while still held on the load pin, is positioned between feed fingers ofthe collar swager; moving the collar swager forward to push the collaragainst the feed fingers and then moving the collar swager to clear theload pin, so that the collar is clear of the load pin; retracting theload pin slide away from the collar swager, wherein the collar is firmlyseated in the feed fingers of the collar swager; advancing the collarswager toward the surface and the fastener inserted through the hole inthe surface; seating the collar on an end of the fastener using thecollar swager, wherein the feed fingers of the collar swager are opened,and the collar is pushed onto the fastener; and swaging the collar onthe fastener using a fastener installation tool.
 19. The method of claim18, further comprising aligning the end effector with regard to one ormore features on the inside surface using a resync camera of the endeffector.
 20. The method of claim 18, further comprising aligning theautomated fastening machine with another machine on an outside of thestructure.
 21. The method of claim 18, further comprising positioningthe end effector relative to the inside surface using a normality sensorof the end effector.
 22. The method of claim 21, wherein the positioningstep comprising rotating the arm and end effector to achieve asubstantially perpendicular orientation relative to the inside surfaceusing signals from the normality sensor.
 23. The method of claim 18,wherein the clamping up step comprises engaging the inside surface andapplying the force using a clamp foot of the end effector.
 24. Themethod of claim 23, further comprising extending the clamp foot toengage the inside surface adjacent the hole using a clamp cylinder ofthe end effector.
 25. The method of claim 18, wherein the force isapplied for a one-up assembly (OUA) process used in the fastening steps.26. The method of claim 18, wherein the swaging step comprises: forcinga swage die down onto the collar using the fastener installation tool,which reduces a diameter of the collar and progressively swages thecollar material into the swage die, wherein installation is completedwhen a pintail of the fastener breaks off.
 27. The method of claim 26,further comprising: retracting the collar swager to strip the swage dieoff the swaged collar, and then vacuuming the pintail out through apintail return tube to a collection point.
 28. The method of claim 18,further comprising inspecting the swaged collar on the fastener.